System and Method for Filtering Inlet Air in an Air Conditioner Air Handler

ABSTRACT

A system for filtering inlet air of an air conditioner air handler, and method of filtering inlet air without a conventional filter, said system is a structure comprising: an air inlet, an air directing structure, a water chamber, positioned within an internal cavity, a structure for directing condensate from an air handler into said water chamber, a drain positioned to impart a maximum water level of water accumulated in said first water chamber; a second air directing structure configured to direct air from said first internal cavity towards an outlet that is affixed to the inlet of an air conditioner air handler.

INDEX TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent application Ser. No. 13/221,522 filed Aug. 30, 2011 the disclosure of which is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

Air conditioner air handlers require regular care and maintenance. One are of care involves the continual changing of an inlet air filter. Filters are changed typically every one to six months. However, many persons fail to change their filters and there is often damage to the air handler.

A system and method is contemplated where an air handler n loner requires a filter.

BRIEF SUMMARY OF THE INVENTION

In one embodiment, the present invention is a system for filtering inlet air of an air conditioner air handler, said system is a structure comprising:

an air inlet; an first air directing structure configured to act in concert with said air inlet to direct air from said air inlet into a first internal cavity; a first water chamber, said water chamber positioned within said first internal cavity such that inlet air passing through said air directing structure directs air above a water level of said first water chamber; a structure for directing condensate from an air handler into said water chamber; a drain positioned to impart a maximum water level of water accumulated from said condensate in said first water chamber; a second air directing structure configured to direct air from said first internal cavity towards an outlet that is affixed to the inlet of an air conditioner air handler.

The system has an air inlet configured to draw in ambient air through a negative pressure differential formed from an inlet fan of an air conditioner air handler.

The system has an air constricting structure incorporated within said first air directing structure.

The system also has a second water chamber positioned above the first water chamber.

The second water chamber is positioned in an airflow stream between the first water chamber and the system outlet where air exits the system and enter the air handler.

Also contemplated is a method of removing particulate from an air conditioner air handler inlet comprising:

providing a structure of claim 1; arranging said structure to connect said structure outlet to an air conditioner air handler inlet in order that said arranging is accomplished with substantially all air exiting the structure entering the air handler; activating said air conditioner air handler, said activating imparting negative pressure in said structure an drawing ambient air into said inlet; directing said ambient air through said first internal cavity and across an upper surface of water in said first water chamber; further directing said ambient air from said first internal cavity to said second air directing structure configured to direct air from said first internal cavity towards an outlet that is affixed to the inlet of an air conditioner air handler; said method removing particulate from said ambient air before said ambient air is directed to said outlet, removal of particulate having efficiency substantially similar to air filtered by a conventional air conditioner air handler filter

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1: A front view of the present invention.

FIG. 2: A right side view of the present invention.

FIG. 3: An opened front view of the present invention.

FIG. 4: A cross section side view of the present invention.

FIG. 5: A cross section side diagram showing air and water flow.

FIG. 6 is a front view of the system of the present invention.

FIG. 7 is a right side view from FIG. 6.

FIG. 8 is a top view from FIG. 6.

FIG. 9 is a side sectional view along section lines from FIG. 6.

FIG. 10 is a side sectional view demonstrative of water flow in the present invention.

FIG. 11 is a side view of one embodiment of the invention.

FIG. 12 is a side view of one embodiment of the invention.

FIG. 13 is a top view of one embodiment of the invention.

FIG. 14 is a side cross section view of one embodiment of the present invention.

FIG. 15 is a side sectional view demonstrative of water flow in the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention includes an assembly 10 that is utilized with existing air conditioner air handlers. The system has a configuration that interacts with the components of an air conditioner air handler. Ambient air 70 is drawn into system 10 through a cavity formed by front frame 14 and lower vertical baffle plate 36. As air is drawn in, it is directed into air constriction area 74 by virtue of air constriction deflector 72. Ambient air is forced into inlet cavity 96 and contacts water 92 positioned in lower water chamber 76. Air continues to flow within the interior portion of lower vertical baffle plate 36 into cavity 97 and over upper water chamber 78 contacting water 94 located in upper water chamber 78. Air flows along first deflecting baffle 34 into cavity 98 and second deflecting middle baffle plate 32 below cavity 99. Upper baffle plate 30 directs air into upper chamber 84 defined by upper wall 28. Airflow continues from the apparatus into the air conditioning air handler as indicated in airflow direction by arrow in FIG. 5. Water positioned in each of lower water chamber 76 and upper water chamber 78 is supplied to the apparatus utilizing condensate water 84 created by the air conditioner air handler and fed by pipe 42 to upper water chamber 78. Upper water chamber 78 fills until exceeding upper water chamber water level 82. Once water exceeds upper chamber water level 82, water travels gravitationally to lower water chamber 76. As water exceeds lower chamber water level 80, water drains through waist water drain 90 and is further directed from the system through drain connector 44 that directs water outward through waist water pipe 54. As previously stated, water travels into the apparatus as is normally collected in an air conditioner air handler condensate.

Article 10 is constructed and arranged to be positioned next to and work with an existing air conditioner air handler. Air handler 58 interfaces with article 10 at gasket 54 which seals the opening and prevents air passing through article 10 from escaping. All air is directed into the air handler. A filter bracket 56 is used to position article 10. Article 10 obviates the need for air handler filters. Support rails 22 support upper perimeter walls 28. A cross brace 16 further provides support to article 10. Inlet hose 50 collects condensate from the air handler and directs collected condensate water 84 into article 10 through inlet tube 42. A lower brace 20 supports the inlet assembly which is formed of inlet frame 14. Ambient air 70 flows into article 10 through an opening as best seen in FIG. 5.

An additional feature in the present invention provides for indication of malfunction the system cease to function properly.

In an embodiment where the lower water chamber 76 fails to drain properly, water 92 rises to a level at or above constrictor 72. Ambient air 70 is prevented from traveling thorough the intended air route in article 10. In such situations, the air handler will freeze due to a lack of inlet air. When the air handler freezes, the air conditioner will cease cooling and an operator will inspect the cause of the malfunction.

This particular system provides for a method of removing impurities such as dirt, dust, allergens and the like from entering a typical air conditioner and air handling system. The system and method of the present invention provides efficiency equal to or greater than conventional fiber filters. As air enters the system, heavier particles such as dust, dirt and allergens contact water in several different locations. These particles when in contact with water will remain in the water and be drawn out of the air flowing through the system. As the water levels accumulate, they eventually collect in the lower most water chamber, which is lower water chamber 76. As the water level in lower water chamber 76 exceeds in lower water chamber 80, water is drained through coupling 48 and water drain 90 eventually to be removed from the system. As will be noted from test results below, the system is shown to greatly reduce dirt, dust and allergens from air transported there through.

The present invention further relates to a method for removing particulate from inlet air traveling into the inlet of an air conditioning air handler.

Typically, filters are utilized for the removal of particulates from air inlet.

The filters need to be changed and have significantly variable levels of efficiency.

A test was performed an air handler with a standard filter against an air handler without a filter in which the apparatus is utilized.

Both tests were performed using Surface Microscopy analysis with an Allergen Screen Check kit.

The Test Results Appear Below:

Test 1

Air Handler with conventional filter.

Particle Identification

OpaqueParticles Skin cell Fragments Insect Biodetritus Total Fibers

Manmade Fibers Total Pollen

Total Fungal Elements/Spores Curvularia species

Total “Other” “Talc-Like” Particles Reddish-Brown Particles Black Particles Method of Analysis: EDLAB SOP•7/13001

The results in this report apply only to the sample(s) specifically listed above and tested at Environmental Diagnostics Laboratory. Unless otherwise noted, samples were received in good condition. Laboratory prepared Quality Control (OC) samples are analyzed with the samples routinely; however, unless a blank (control) is received, the result for the control is not compared. Quantitative data is based on 3 significant figures; Grand Total may not equal 100% due to rounding.

Opaque Particles Identified from Tape Prep Assays Opaque Particles

-   -   These particles may originate from inorganic or organic sources         in nature. However, it appears opaque when observed under light         microscopy. It has various shape and sizes. It may be regular or         irregular in shape. On an average it can be measured less than         one micron to well over fifty microns with some exceptions.         Commonly these particles include but are not limited to dust &         debris, paint, combustions, emission, ash, silica and others.

These particulates are significant from a health/allergy point of view especially in case of respiratory disorder.

Fibers Identified from Tape Prep Assays

-   -   Man-made fibers may come from natural raw materials like         cellulose or from synthetic chemicals like rayon, nylon, etc. In         indoor environments, some important sources of man made fiber         include carpet. cellulose based building materials, clothing,         paper and paper products, etc. Size of these fibers varies from         a few microns to a few millimeters; however, an average size         range may be 1 micron to over 500 microns. Health implications         of these particles are not well described. however some of the         man-made fibers are important from an allergy point of view         especially for dermal allergy.         Spores I Fungal Elements Identified from Tape Prep Assays

Curvularia Species

-   -   Curvularia species are found worldwide and are very common. The         hyphae, conidiophores, and conidia are pigmented         olivaceous-brown (dematiaceous). They can be isolated from the         air, plants (especially grasses), sand dune soil, and soil.         Rarely, they can be an opportunist human pathogen causing         allergic reactions, eye (corneal) infections, mycetoma, and         infections in immunocompromiSed patients.

Other Material Identified from Tape Prep Assays

“Talc-Like” Particles

-   -   These are thin disk-like particles of variable size range (10 to         50 micron), It may be organic or inorganic in nature. In indoor         environment these particles mainly come from cornmeal, other         grain flour, talcum powder etc. Some of these particles may         adversely influence the health of dweller (example talcum         powder).

Black Particles

-   -   These microscopic particles may originate from an organic source         material. They greatly vary in their shape and sizes depending         on their origin. However, an average size ranges between         1-micron to 5 micron with some exceptions. It may be regular or         irregular in shape. In the indoor environment some important         source/cause of these particles includes but are not limited to         combustion, burning of oil & candles, chimney shoot, automobile         exhaust, neoprene (rubber compound that applied to the inside         surface of fiber glass duct liner), and other organic materials         emitted by copier machines, printers, abraded paints etc. These         particles may influence health and hygienic condition of         dwellers.

Reddish-Brown Particles

-   -   These microscopic particles may originate from inorganic or         organic source materials. In indoor environments these particles         mainly come by rusting, coarse, weathering of materials etc.         They may also be released into the environment due to         deterioration of wood or wood products, art and sculpture work         etc. These particles greatly vary in their shape and sizes. It         can be measured from a few micron to over 100-microns. This         particle may be the indicator of moisture problem in indoor         environment.     -   The health implications of this material are not well         established however; it may be significant from a health and         hygiene point of view.

TABLE 1 Total Count Percent of Particle Identification Raw Count (Cts/cm²) Total Count OpaqueParticles 127 6,350 92.4% Skin Cell Fragments 49 196 2.85% Insect Biodetritus BDL BDL N/A Total Fibers 18 72 1.05% Manmade Fibers 18 72 1.05% Total Pollen BDL BDL N/A Total Fungal Elements/Spores 2 8 0.116%  Dematiaceous Fungal Hyphal 1 4 0.0582%  Elements Dematiaceous Fungal Spore 1 4 0.0582%  Elements Total “Other” 62 248 3.61% Reddish-Brown Particles 17 68 0.99% Black Particles 45 180 2.82% Total Counts: 258 6,870 99.9% BDL = Below Detection Limit: No particles were reported from the microscopically observed area on the specimen slide (at 10 × 10 or 10 × 40 magnification).

Table 1 and FIGS. 6 and 7 show significant particulate detected in the inlet air.

Test 2

The experiment was repeated utilizing the system of the present invention in an air handler with no filter in place.

TABLE 2 Percent of Total Count Total Particle Identification Raw Count (Cts/cm²) Count OpaqueParticles 221 884 90.9% Skin Cell Fragments 4 16 1.65% Insect Biodetritus BDL BDL N/A Total Fibers 1 4 0.412%  Manmade Fibers 1 4 0.412%  Total Pollen BDL BDL N/A Total Fungal Elements/Spores 1 4 0.412%  Cuvularia species 1 4 0.412%  Total “Other” 16 64 6.58% “Talc-Like” Particles 2 8 0.82% Reddish-Brown Particles 3 12 1.23% Black Particles 11 44 4.53% Total Counts: 243 972  100% BDL = Below Detection Limit: No particles were reported from the microscopically observed area on the specimen slide (at 10 × 10 or 10 × 40 magnification).

Surface Microscopy (Tape Prep Assays)

Opaque Particles Identified from Tape Prep Assays

Opaque Particles

-   -   These particles may originate from inorganic or organic sources         in nature. However, it appears opaque when observed under light         microscopy. It has various shape and sizes. It may be regular or         irregular in shape. On an average it can be measured less than         one micron to well over fifty microns with some exceptions.         Commonly these particles include but are not limited to dust &         debris, paint, combustions, emission, ash, silica and others.

These particulates are significant from a health/allergy point of view especially in case of respiratory disorder.

Fibers Identified from Tape Prep Assays

Man-Made Fibers

-   -   Man-made fibers may come from natural raw materials like         cellulose or from synthetic chemicals like rayon, nylon, etc. In         indoor environments, some important sources of man made fiber         include carpet. cellulose based building materials, clothing,         paper and paper products, etc. Size of these fibers varies from         a few microns to a few millimeters; however, an average size         range may be 1 micron to over 500 microns.

Health implications of these particles are not well described. however some of the man-made fibers are important from an allergy point of view especially for dermal allergy.

Spores I Fungal Elements Identified from Tape Prep Assays

Curvularia Species

-   -   Curvularia species are found worldwide and are very common. The         hyphae, conidiophores, and conidia are pigmented         olivaceous-brown (dematiaceous). They can be isolated from the         air, plants (especially grasses), sand dune soil, and soil.         Rarely, they can be an opportunist human pathogen causing         allergic reactions, eye (corneal) infections, mycetoma, and         infections in immunocompromiSed patients.

Other Material Identified from Tape Prep Assays

“Talc-Like” Particles

-   -   These are thin disk-like particles of variable size range (10 to         50 micron), It may be organic or inorganic in nature. In indoor         environment these particles mainly come from cornmeal, other         grain flour, talcum powder etc. Some of these particles may         adversely influence the health of dweller (example talcum         powder).

Black Particles

-   -   These microscopic particles may originate from an organic source         material. They greatly vary in their shape and sizes depending         on their origin. However, an average size ranges between         1-micron to 5 micron with some exceptions. It may be regular or         irregular in shape. In the indoor environment some important         source/cause of these particles includes but are not limited to         combustion, burning of oil & candles, chimney shoot, automobile         exhaust, neoprene (rubber compound that applied to the inside         surface of fiber glass duct liner), and other organic materials         emitted by copier machines, printers, abraded paints etc. These         particles may influence health and hygienic condition of         dwellers.

Reddish-Brown Particles

-   -   These microscopic particles may originate from inorganic or         organic source materials. In indoor environments these particles         mainly come by rusting, coarse, weathering of materials etc.         They may also be released into the environment due to         deterioration of wood or wood products, art and sculpture work         etc. These particles greatly vary in their shape and sizes. It         can be measured from a few micron to over 100-microns. This         particle may be the indicator of moisture problem in indoor         environment.     -   The health implications of this material are not well         established however; it may be significant from a health and         hygiene point of view.

As seen from the reported results, an air handler without a filter would be expected to have significant increase in particulate.

This was not the case. The congruity of results indicates that the system of the present invention provides particulate filtration similar to filtration results when using an air filter.

In one embodiment, an additive is added to system 10. Additives include, but are not limited to materials such as, aromatic, antimicrobial, anti fungal, anti-mole, anti-spore, or combinations thereof.

One embodiment adds the additive to at least one water chamber. The additive can be a solid, semi solid or liquid.

One embodiment provides an additive as a solid in which the additive is released over an extended period of time being 1-90 days.

In one embodiment, addition of anti-mold materials is a step in a method to clean mold from duct work.

The Method Includes the Steps of

providing a an article/system of the present invention; adding a mold killing or remediation component to the water chamber of the article; running the air conditioner such that the mold killing component is carried through the system, into the existing air handler; dispersing the mold killing component through the air conditioning ductwork; wherein the method is carried out for 1-90 days until mold is killed and no longer in the ductwork.

This method can be used to sterilize and deodorize air ducts. The method is not limited to distribution of a single additive and can be used with a plurality of additives.

The present invention has an additional feature in that there is no need to clean or change the water in any water chamber.

Particulate in the inlet air 70 is directed into water in a water chamber. Air pressure from the system circulates water in all water chambers such that particulate is not able to settle or accumulate. The particulate circulates in the water. As water levels rise above the aforementioned drainage heights, particulate is carried out of the article 10 and ultimately deposited outside article 10 though drain 48.

In one embodiment, as demonstrated in FIGS. 6-10, a secondary recycling system 100 includes return water chamber 102 having an inlet port 104 and pump 108 positioned within water chamber 102. Pump 108 being a submersible pump and configured with a pump inlet 106 and a water return pipe 110 operatively associated with pump 108. As best demonstrated in FIG. 9, water from system 10 enters return water chamber 102 gravitationally through inlet 104. System 100 is constructed and arranged whereby water 118 has an upper water level 80 is maintained by virtue of water level position relative to placement of outlet pipe 112 constructed with water chamber 102. Weir dam plate 114 facilitates sludge removal by virtue of weir dam disposal 116.

As generally understood, a weir is a barrier across a moving fluid configured to alter its flow characteristics. AS used herein and understood, the weir of the present system includes, but is not limited to:

a labyrinth weir that is constructed using a trapezoidal-shaped weir wall geometry (plan view) to increase the weir length; broad-crested weir is a flat-crested structure, with a long crest compared to the flow thickness; sharp-crested weir which allows the water to fall cleanly away from the weir. Sharp crested weirs are typically ¼″ [6.35 mm] or thinner metal plates. Sharp crested weirs come in many different shapes and style, such as Rectangular (with and without end contractions), V-notch and Cipolletti weirs.

Compound weirs which include combinations of sharp crested weirs can be considered into three groups according to the geometry of weir: a) the rectangular weir, b) the V or triangular notch, and c) special notches, such as trapezoidal, circular, or parabolic weirs.

V-notch weir is a triangular channel section, used to measure small discharge values. The upper edge of the section is always above the water level, and so the channel is always triangular simplifying calculation of the cross-sectional area.

This particular configuration accounts for particulate trapped in the water system of the present invention and provides for accumulation and removal of accumulated particulate matter or sludge 120.

In one embodiment, the configuration incorporating a weir increases the efficiency of particulate removal.

It is also contemplated, and demonstrated in FIGS. 11-15 that the system be provided without the aforementioned weir components. The configuration providing return pipe 202 that directs water from pump 102 back into the interior of main housing 12.

As discussed herein, the system of the present invention has been tested and particulate analysis demonstrates significant reduction in particulate matter in air handling systems according to the present invention.

While the invention has been described in its preferred form or embodiment with some degree of particularity, it is understood that this description has been given only by way of example and that numerous changes in the details of construction, fabrication, and use, including the combination and arrangement of parts, may be made without departing from the spirit and scope of the invention. 

I claim:
 1. A system for filtering inlet air of an air conditioner air handler, said system is a structure comprising: an air inlet; an first air directing structure configured to act in concert with said air inlet to direct air from said air inlet into a first internal cavity; a first water chamber, said water chamber positioned within said first internal cavity such that inlet air passing through said air directing structure directs air above a water level of said first water chamber; a structure for directing condensate from an air handler into said water chamber; a drain positioned to impart a maximum water level of water accumulated from said condensate in said first water chamber; and a water pump configured to be operatively associated with an inlet and an outlet.
 2. The system of claim 1 wherein said air inlet is configure to draw in ambient air through a negative pressure differential formed from an inlet fan of an air conditioner air handler.
 3. The system of claim 1 further comprising an air constricting structure incorporated within said first air directing structure.
 4. The system of claim 1 further comprising a second second water chamber positioned above said first water chamber.
 5. The system of claim 4 where said second water chamber is positioned to receive condensate from an air conditioner air handler.
 6. The system of claim 4 where said second water chamber is positioned to receive condensate from an air conditioner air handler wherein said water pump is in said second chamber.
 7. The system of claim 4 where said second water chamber has an outlet positioned and configured for removing accumulated solid particulate in said chamber.
 8. The system of claim 4 where said second water chamber is configured with w weir dam plate configured for accumulating particulate and ultimately directing said accumulated particulate into an outlet positioned and configured for removing accumulated solid particulate in said chamber.
 9. A method of removing particulate from an air conditioner air handler inlet, said method comprising: providing a structure of claim 1; arranging said structure to connect said structure outlet to an air conditioner air handler inlet in order that said arranging is accomplished with substantially all air exiting the structure entering the air handler; activating said air conditioner air handler, said activating imparting negative pressure in said structure an drawing ambient air into said inlet; directing said ambient air through said first internal cavity and across an upper surface of water in said first water chamber; further directing said ambient air from said first internal cavity to said second air directing structure configured to direct air from said first internal cavity towards an outlet that is affixed to the inlet of an air conditioner air handler; said method removing particulate from said ambient air before said ambient air is directed to said outlet, removal of particulate having efficiency substantially similar to air filtered by a conventional air conditioner air handler filter. 